CN110275511A - Automatic test equipment suitable for power motor controller hardware - Google Patents
Automatic test equipment suitable for power motor controller hardware Download PDFInfo
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- CN110275511A CN110275511A CN201910553714.8A CN201910553714A CN110275511A CN 110275511 A CN110275511 A CN 110275511A CN 201910553714 A CN201910553714 A CN 201910553714A CN 110275511 A CN110275511 A CN 110275511A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
- G05B23/0213—Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0256—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system
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- Engineering & Computer Science (AREA)
- Automation & Control Theory (AREA)
- Control Of Electric Motors In General (AREA)
Abstract
The present invention provides a kind of automatic test equipment suitable for power motor controller hardware, comprising: fixture, signal converting case, detecting and analysing system and load box, fixture is for clamping measurand;Institute's signal converting case is used for jockey and detecting and analysing system, realizes signal converting between the two;Detecting and analysing system includes cabinet, high voltage power supply and programmable power supply, and industrial personal computer and test board are provided in cabinet, and test board includes matrix card, CAN interface card, D/A transition card, oscillograph card, multimeter card and rotation varying signal analog card;Load card is provided in load box, the load for needing when simulation test.The present invention can facilitate the maintenance of project replacement and test case, and improve simulation precision and reduce cost.
Description
Technical field
The present invention relates to the automatic test technology of controller hardware, in particular to the power motor controller of 50KW or more is hard
The automatic test equipment of part.
Background technique
Power motor inverter hardware Auto-Test System is used to carry out functional test to electronic control unit hardware, is automobile electricity
The automation of sub- hardware control unit, quick functional test platform.The system is passed through by powering to electronic control unit hardware
The real-time switching of internal relay matrix card, the analog signal of the generation of various instruments, board inside bonding apparatus, is realized automatically controlled
The simulation input of unit external sensor signal, and the real-time connection to different loads in load card.
Orthodox car electronics automatically testing platform is mainly for engine mission controller, mainly classical signal mould
It is quasi-, such as crankshaft cam axis signal, simulation numeral amount and conventional load detection, such as fuel injector ignition coil and low-power machine.
Motor inverter hardware capability test macro adopts the signals such as voltage, electric current using internal various instrument, board
Sample realizes signal processing and analysis, carries out rotation varying signal simulation, and to high pressure and high current signal acquisition, provides according to user
Parameters index generates test analysis report, completes the functional test to motor inverter electronic control unit hardware.
But test macro in the prior art does not have the function of being tested power motor, cannot achieve pair
The test of power motor.
Summary of the invention
Example technical problems to be solved of the invention are to provide a kind of function of having and tested power motor
Automatic test equipment.
The technical solution adopted by the present invention are as follows:
The embodiment of the present invention provides a kind of automatic test equipment suitable for power motor controller hardware, comprising: fixture,
Signal converting case, detecting and analysing system and load box, the fixture is for clamping measurand;The signal converting case is for connecting
The fixture and the detecting and analysing system are connect, realizes signal converting between the two;The detecting and analysing system include cabinet,
High voltage power supply and programmable power supply, are provided with industrial personal computer and test board in the cabinet, the test board include matrix card,
CAN interface card, D/A transition card, oscillograph card, multimeter card and rotation varying signal analog card;Load is provided in the load box
Card, the load for being needed when simulation test;Wherein, it is stored with test case in the industrial personal computer, is used for according to testing requirement,
Selectivity controls the test board, the programmable power supply, the high voltage power supply and the load card and executes automatic test, and base
Analysis report is automatically generated in test result, the test case includes resistance test, driving between high-low pressure test, pin terminals
Semiotic function test, analog signal functional test, numeral input test, diagnostic function test, overvoltage protection signal test, pin
Resistance test, rotation variable signal test and PWM driving output test over the ground.
Optionally, when executing automatic test, the test case is converted into executable TestStand text.
Optionally, the load card includes high power load card, middle power termination card and low-power load card, the big function
Rate load card be used for be more than 10A load simulation, the middle power termination card for motor and various valve classes load simulation, institute
Low-power load card is stated for 1A low-power load simulation below.
Optionally, the signal converting case also provides for short circuit and high voltage protective.
Optionally, the high voltage power supply is the high voltage power supply of 600V, and the programmable power supply is the low-tension supply of 14V.
Optionally, the measurand is communicated using inquiry/response communication agreement.
Optionally, the cabinet is PXI cabinet.
Automatic test equipment provided in an embodiment of the present invention suitable for power motor controller hardware, can facilitate project
The maintenance of replacement and test case, when increasing or modifying test case, it is only necessary to modify TestStand text, revolve varying signal
Simulation both improves simulation precision, also reduces cost, while being easily formed closed loop, high-voltage detecting method is easy to protect high-voltage electricity
Road, CAN waveform and current waveform detection method, are easy to quantify test result, are beneficial to the mathematical statistics to test result.
Detailed description of the invention
Fig. 1 is the structural frames of the automatic test equipment provided in an embodiment of the present invention suitable for power motor controller hardware
Figure;
Fig. 2 accompanies survey software flow pattern for the embodiment of the present invention;
Fig. 3 is the signal principle figure of rotary transformer;
Fig. 4 is the signal resolution schematic diagram of rotary transformer;
Fig. 5 is high pressure detection schematic diagram;
Fig. 6 and Fig. 7 is CAN and current waveform detection schematic diagram.
Specific embodiment
To keep the technical problem to be solved in the present invention, technical solution and advantage clearer, below in conjunction with attached drawing and tool
Body embodiment is described in detail.
Electric machine controller involved in the embodiment of the present invention and driver are the control and driving for controlling permanent magnet synchronous motor
Circuit is the power motor master control system on hybrid power car and pure electric sedan, main to drive 140KW power power train in vehicle application
Motor.Matching vehicle can are as follows: a vapour car company X40EV, the Jilin Pentium B50EV, B50PHEV automobile R7EV and day vapour A2SUV
EV etc..
As shown in Figure 1, the automatic test equipment packet provided in an embodiment of the present invention suitable for power motor controller hardware
Include: fixture 1, signal converting case 2, detecting and analysing system 3 and load box 4, the fixture 1 is for clamping measurand;The letter
Number transfer box 2 realizes signal converting between the two for connecting the fixture 1 and the detecting and analysing system 3;The test
Analysis system 3 includes cabinet 301, high voltage power supply 302 and programmable power supply 303, is provided with industrial personal computer and test board in the cabinet
Card, the test board include matrix card, CAN interface card, D/A transition card, oscillograph card, multimeter card and rotation varying signal simulation
Card;It is provided with load card in the load box, the load for needing when simulation test;Wherein, it is stored in the industrial personal computer
Test case, for according to testing requirement, selectivity control the test board, the programmable power supply, the high voltage power supply and
The load card executes automatic test, and automatically generates analysis report based on test result, and the test case includes high-low pressure
Resistance test, driving signal functional test, analog signal functional test, numeral input test, diagnosis function between test, pin terminals
It can resistance test, rotation variable signal test and the PWM driving output test over the ground of test, overvoltage protection signal test, pin.
In embodiments of the present invention, measurand is electric machine controller, can be specifically arranged according to actual needs, such as motor control
The control panel of device processed and driving plate etc..Measurand can be clamped on fixture by way of clamping, and pass through connector and letter
The connection of number transfer box.
In embodiments of the present invention, cabinet can be PXI cabinet, in this way, each test board can pass through PXI interface and tested pair
As connection.Signal converting case also provides for short circuit and high voltage protective, can be VPC signal converting case.
In embodiments of the present invention, the load card includes high power load card, middle power termination card and low-power load
Card, the high power load card be used for be more than 10A load simulation, such as power motor, oil spout igniting simulate;The middle power
Load card is used for the load simulation of motor and various valve classes, and the low-power load card is used for 1A low-power load mould below
It is quasi-.
In embodiments of the present invention, the high voltage power supply is the high voltage power supply of 600V, and the programmable power supply is the low pressure of 14V
Power supply.
In embodiments of the present invention, the measurand is communicated using inquiry/response communication agreement.Implement in the present invention
In example, measurand uses inquiry/response communication agreement, does not use AUTOSAR operating system, but introduces the hand-written operation of third party
System detects hardware information, so that security performance is high, reduces processing speed to complete the detection stateful to hardware
It is transmitted with CAN message.It is provided in measurand and accompanies survey software, for cooperating automatic test, facilitate monitoring electric machine controller hard
Part state.This accompanies the process for surveying software can be as shown in Figure 2.It is mainly comprised the steps that as shown, accompanying and surveying software
(1) hardware initialization, including configurable clock generator source, configuration timer, configuration CAN module, configuration PWM, configuration interrupt,
Configure AD conversion and I/O port;
(2) hardware setting initial value, including I/O port original state and PWM frequency;
(3) system variable setting disposition, the initial value including CAN caching initial value, AD caching initial value and state machine.The
Four starting AD acquisitions, including setting AD is interrupted, is obtained three road current of electric, judgement saves current value, is obtained and is done sensor confession
Piezoelectric voltage saves data and setting task list;
(4) start timed task, start round-robin, last main program setting while (1) brings into operation.
In embodiments of the present invention, matrix card is measuring signal channel switch, is used for switching signal;CAN interface card is used for
CAN signal receives;For D/A transition card for sending simple analog signal, such as simulation includes crankshaft cam axis hypodontia signal, magnetoelectricity letter
Number equal special waveforms;For oscillograph card for acquiring signal and carrying out data analysis, the result after analysis is sent to industrial personal computer;General-purpose
Table card is used to measure the outside port voltage of measurand, line resistance and capacitor etc.;Varying signal analog card is revolved for simulating rotation
Varying signal.Wherein, it is provided with test software in industrial personal computer, D/A transition card and rotation varying signal analog card, which can be divided into
Three layers.First layer is labview bottom layer driving, is responsible for being managed equipment and handling information.The second layer is master control
Layer, for managing board resource, device resource and it being called to be communicated, and passes to the information of each board and device resource
Managed application data-layer.Third layer is managed application data-layer, and TestStand software is responsible for test case management, by the testing requirement of project
It is converted into test language, and test result is analyzed, generates test report etc..
In embodiments of the present invention, to the concrete model of each test board, there is no limit as long as can be realized corresponding function
Energy.In a non-limiting embodiments, D/A transition card sampling parameter is 750KHZ 16, and rotation varying signal analog card can be
The FPGA card PXI-7841R of NI.
Based on above-mentioned configuration, the automatic test equipment of the embodiment of the present invention at least has following functions:
[simulation of rotation varying signal]
Signals of rotating transformer principle is as shown in Figure 3.R1, R2 are excitation signal, are that electric machine controller generates, S1-S3,
S2-S4 is the orthogonal feedback signal of two-way, and test macro is needed to simulate.It is true to rotate when motor rotates to different location
On the voltage induced to the S1-S3 and S2-S4 of different angle that transformer can be such that R1-R2 generates, because incude the reason of angle
Voltage is different, by realizing the parsing to angle to the decoding of S1-S3 and S2-S4 signal.Test equipment is according to this principle
Realize signals of rotating transformer simulation.
Signals of rotating transformer Analytic principle is as shown in Figure 4.Signals of rotating transformer (S1-S3, the S2- that load box generates
S4), there is stringent phase requirements (i.e. angle corresponding relationship) with input signal, can support the analog frequency of 10KHz and 20KHz.
Angle between transformer signal and input signal is consecutive variations, for example is numerically changed with 0.1 degree or 0.01 degree.
The signal of S1-S3, S2-S4 are that excitation signal incudes, and under fixed angle, waveform is fixed as schemed.Wherein electrical angle is
It is excitation signal that motor, which rotates angle Excitation signal, and SINMNT is S1-S3 signal, and COSMNT is S2-S4 signal.
Wherein:
Excitation signal: Asin ω t
Sinusoidal angle signal: k × Asin ω × tsin θ
Complementary chord angle signal: k × Asin ω × tcos θ
A: excitation amplitude ω: excitation frequency k: rotation becomes transformation ratio θ: rotor angle
Based on the relative theory of above-mentioned signals of rotating transformer, in embodiments of the present invention, the FPGA card PXI- of NI is used
7841R completes the simulation of rotation varying signal, the excitation generated using 16 analog input channel acquisition measurands of board 750KHZ
Signal calculates cosine and sine signal using 40MHZ logical unit (for the FPGA computing module in the PXI-7841R of NI), so
Afterwards by 1MHZ, D/A transition card is exported to measurand.This Fang An is used to true rotation described in simulation drawing 2 and becomes, shown in Fig. 3
Angle variation be made into algorithm write-in FPGA.
[signal imitation]
In the embodiment of the present invention, quilt is generated using signal generator (including D/A transition card and rotation varying signal analog card etc.)
Survey the waveform that object needs;Using multimeter card measurement port voltage, line resistance and capacitor;It is simulated using D/A transition card special
Different waveform;Signal is acquired using oscillograph card and carries out data analysis, such as acquisition CAN waveform and current waveform, and analysis is thereon
The characteristic value along time and current waveform is risen, analysis method is that the waveform of acquisition is made into array, then in labview software
The feature decomposition of these arrays is come out, such as rising time, it is low level that some voltage is lower than in array, is higher than some
Voltage is high level, and the intermediate data amount check * sampling time is the rise time;Driving load is provided using load card, is made
Programmable power supply is provided with programmable power supply;It is attached using mature and stable board resource and tested ECU (with special PXI
Interface connection), do input/output interface use;Using relay board switching equipment resource, using limited equipment to tested pair
As carrying out omnidirectional high-accuracy measurement.Master control system is used to manage board resource, device resource and it is called to be communicated, and handle
The information of each board and device resource passes to labview bottom layer driving.Labview bottom layer driving is responsible for being managed equipment
And information is handled.TestStand software is responsible for test case management, and the testing requirement of project is converted into test language
Speech, and test result is analyzed, generate test report etc..
Different from traditional automatic testing scheme, the embodiment of the present invention needs to do high voltage protective processing at signal converting case,
Signal generator is divided into two parts (having conventional function generator and special waveform generator), traditional standard signal such as PWM wave
Shape can be write direct, signal such as crankshaft cam axis hypodontia signal, magnetoelectricity signal and rotation varying signal for needing algorithm to support etc.
It needs that FPGA is written in algorithm after host computer finishes writing program.
[signal stabilization analysis]
In the case where considering measurement performance, measuring system must solve the differentiation between component (referring to measurand).
And this differentiation is caused by standard deviation.The same sample is repeated to do 50 measurements, it is ensured that its biasing range is in system
In allowed band.Because tested sample is more, the sample of annual 200K is normally had, so limit value needs to find out certain sample
Mean value and variance carry out limit value setting.Sample is exactly the sample in probability theory.Allowed band refers to the minimum that design allows
Deviation, and can guarantee First Pass Yield when high-volume is tested, if range is excessive, it will lead to faulty sample outflow, range
It is too small will lead to test could repeatedly pass through.
Load signal high pressure detection schematic diagram is as shown in Figure 5.0~600V of load voltage range is in supply voltage 540V system
Failure diagnosis information (concussion waveform i.e. shown in Fig. 4) is at least captured in 30us from the moment for connecting high pressure under overvoltage condition.
This test is different from orthodox car Electronic Testing, needs high voltage power supply cooperation to generate 600V high pressure, while to high pressure return signal
It is accordingly tested, needs to add high-voltage signal on hardware configuration and high pressure detection configures program-controlled high-voltage electricity outside PXI cabinet
Source needs on software algorithm cooperation detection that using oscillograph card detection fault pin waveform, collected waveform is changed into number
Group judges maximin and frequency etc..
[CAN waveform modelling]
CAN waveform and current waveform detection are as shown in Figure 6 and Figure 7.CAN waveform rise and fall time is detected, with
Guarantee CAN communication failure rate and frame loss rate in system tolerance interval.To electric current rise and fall time, size of current and acting
Size carries out quantification of targets, i.e., constrains these indexs, such as rising edge in 7-9us with limit value, acting is in 100 joule of -120 coke
Ear.Drive current waveform is detected, does work value satisfaction by the function of driven object to guarantee driving circuit within the unit time
Rate output requires and its EMC performance is detected, and tests the key point of its current waveform.
Automatic test equipment provided in an embodiment of the present invention can be realized the test case for electric machine controller hardware,
When executing automatic test, convert test cases to executable TestStand text, can facilitate test case maintenance and
Management, mathematical analysis and generation test report including result etc..The TestStand text of generation calls each resource
Labview bottom layer driving, for example the resource of multimeter card is called to carry out voltage acquisition, the signal of voltage acquisition is from tested pair
As, measurand output voltage passes to VPC signal converting case by fixture, passes to multimeter after carrying out signal protection,
Labview bottom layer driving calls multimeter resource to be worked and fetches result by PXI bus.Wherein, the height of power supply chip
Low voltage experiment passes through programmable power supply, and resistance test passes through load by multimeter card, driving signal functional test between pin terminals
Card and oscillograph card, analog signal functional test pass through load by multimeter card, numeral input test and diagnostic function test
Card, overvoltage protection signal pass through rotation varying signal analog card, PWM driving by high voltage power supply and oscillograph card, rotation variable signal test
Output detection passes through oscillograph card.
Below by taking the test of the high-low pressure of power supply chip and rotation variable signal test as an example, automatic equipment of the invention is realized
Function is further described.
[high-low pressure test]
High-low pressure test case is converted into executable TestStand text, setting needs the high-low pressure voltage carried out
Value, and the controlled device return value for needing to judge is subjected to limit value setting, labview bottom layer driving is called, programmable power supply is controlled
Voltage change is carried out, voltage data is passed to power supply by cable interface, passed through after voltage change by labview bottom layer driving
VPC signal converting case passes to the measurand in fixture, because of the variation of voltage, leads to measurand affected inwards,
The voltage value of output passes to multimeter by fixture and VPC signal converting case, is passed to after multimeter acquisition by PXI bus
Then labview bottom layer driving is called by TestStand text, form closed loop.
[rotation variable signal test]
The first step issues pumping signal from measurand electric machine controller;
Second step is acquired by the A/D module in FPGA card module, is converted into voltage waveform;
Third step, the test case provided by software algorithm notify the angle of the host test in PXI cabinet or turn
Speed;
4th step, host pass to angle information or rotary speed information by software-driven the algorithm in FPGA card module
Module;
5th step, FPGA card algoritic module calculate the voltage value for needing to generate;
Voltage value is passed to the D/A module in FPGA card by the 6th step;
7th step, the D/A module in FPGA card give voltage output to measurand electric machine controller;
8th step, measurand electric machine controller calculates voltage value automatically and the relationship of pumping signal obtains angle or turns
Speed;
9th step, CAN signal of uniting measurand electric machine controller pass to angle or rotary speed information in PXI cabinet
CAN interface card;
The information PXI bus in PXI cabinet of uniting is passed to PXI host by the tenth step, CAN interface card, and host is according to
Whether the result that the pre-designed angle of three steps or tachometer value judge that controlled device calculates automatically in the 8th step is correct;
The result of judgement and obtained data are generated report by the 11st step.
To sum up, the automatic test equipment provided in an embodiment of the present invention suitable for power motor controller hardware, Neng Goufang
Just the maintenance of project replacement and test case, when increasing or modifying test case, it is only necessary to modify TestStand text, revolve
Varying signal simulation both improves simulation precision, also reduces cost, while being easily formed closed loop, high-voltage detecting method is easy to protect
High-tension circuit, CAN waveform and current waveform detection method, are easy to quantify test result, are beneficial to the mathematics to test result
Statistics.
Embodiment described above, only a specific embodiment of the invention, to illustrate technical solution of the present invention, rather than
It is limited, scope of protection of the present invention is not limited thereto, although having carried out with reference to the foregoing embodiments to the present invention detailed
Illustrate, those skilled in the art should understand that: anyone skilled in the art the invention discloses
In technical scope, it can still modify to technical solution documented by previous embodiment or variation can be readily occurred in, or
Person's equivalent replacement of some of the technical features;And these modifications, variation or replacement, do not make corresponding technical solution
Essence is detached from the spirit and scope of technical solution of the embodiment of the present invention, should be covered by the protection scope of the present invention.Therefore,
The protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (7)
1. a kind of automatic test equipment suitable for power motor controller hardware characterized by comprising fixture, signal turn
Case, detecting and analysing system and load box are connect, the fixture is for clamping measurand;The signal converting case is described for connecting
Fixture and the detecting and analysing system, realize signal converting between the two;The detecting and analysing system includes cabinet, high-voltage electricity
Source and programmable power supply are provided with industrial personal computer and test board in the cabinet, and the test board includes matrix card, CAN interface
Card, D/A transition card, oscillograph card, multimeter card and rotation varying signal analog card;It is provided with load card in the load box, is used for
The load needed when simulation test;
Wherein, be stored with test case in the industrial personal computer, for according to testing requirement, selectivity control the test board,
The programmable power supply, the high voltage power supply and the load card execute automatic test, and automatically generate analysis based on test result
Report, the test case include resistance test, driving signal functional test, analog signal between high-low pressure test, pin terminals
Functional test, numeral input test, diagnostic function test, overvoltage protection signal test, pin over the ground resistance test, rotation varying signal
Test and PWM driving output test.
2. automatic test equipment according to claim 1, which is characterized in that when executing automatic test, the test is used
Example is converted into executable TestStand text.
3. automatic test equipment according to claim 1, which is characterized in that the load card include high power load card,
Middle power termination card and low-power load card, the high power load card be used for be more than 10A load simulation, the middle power bear
The load simulation that card is used for motor and various valve classes is carried, the low-power load card is for 1A low-power load simulation below.
4. automatic test equipment according to claim 1, which is characterized in that the signal converting case also provides for short circuit
And high voltage protective.
5. automatic test equipment according to claim 1, which is characterized in that the high voltage power supply is the high-voltage electricity of 600V
Source, the programmable power supply are the low-tension supply of 14V.
6. automatic test equipment according to claim 1, which is characterized in that the measurand is assisted using inquiry/response communication
View is communicated.
7. automatic test equipment according to claim 1, which is characterized in that the cabinet is PXI cabinet.
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